GATE Questions & Answers of Sheet (Shearing, Deep Drawing, Bending) Metal Forming Processes

What is the Weightage of Sheet (Shearing, Deep Drawing, Bending) Metal Forming Processes in GATE Exam?

Total 13 Questions have been asked from Sheet (Shearing, Deep Drawing, Bending) Metal Forming Processes topic of Casting, Forming and Joining Processes subject in previous GATE papers. Average marks 1.85.

In a sheet metal of 2 mm thickness a hole of 10 mm diameter needs to be punched. The yield strength in tension of the sheet material is 100 MPa and its ultimate shear strength is 80 MPa. The force required to punch the hole (in kN) is __________

With respect to metal working, match Group A with Group B:

Group A Group B
P: Defect in extrusion I: alligatoring
Q: Defect in rolling II: scab
R: Product of skew rolling III: fish tail
S: Product of rolling through cluster mill IV: seamless tube
  V: thin sheet with tight tolerance
  VI: semi-finished balls of ball bearing

A mild steel plate has to be rolled in one pass such that the final plate thickness is 2/3rd of the initial thickness, with the entrance speed of 10 m/min and roll diameter of 500 mm. If the plate widens by 2% during rolling, the exit velocity (in m/min) is _______

A rectangular hole of size 100 mm × 50 mm is to be made on a 5 mm thick sheet of steel having ultimate tensile strength and shear strength of 500 MPa and 300 MPa, respectively. The hole is made by punching process. Neglecting the effect of clearance, the punching force (in kN) is

Match the following metal forming processes with their associated stresses in the workpiece.

Metal forming process                Type of stress
1. Coining P. Tensile
2. Wire Drawing Q. Shear
3. Blanking R. Tensile and compressive
4. Deep Drawing S. Compressive

 

Calculate the punch size in mm, for a circular blanking operation for which details are given below.

Size of the blank 25 mm
Thickness of the sheet 2 mm
Radial clearance between punch and die 0.06 mm
Die allowance 0.05 mm

The shear strength of a sheet metal is 300 MPa. The blanking force required to produce a blank of 100 mm diameter from a 1.5 mm thick sheet is close to

In a shear cutting operation, a sheet of 5mm thickness is cut along a length of 200mm. The cutting blade is 400mm long and zero-shear (S=0) is provided on the edge. The ultimate shear strength of the sheet is 100MPa and penetration to thickness ratio is 0.2. Neglect friction.

Assuming force vs displacement curve to be rectangular, the work done (in J) is

In a shear cutting operation, a sheet of 5mm thickness is cut along a length of 200mm. The cutting blade is 400mm long and zero-shear (S=0) is provided on the edge. The ultimate shear strength of the sheet is 100MPa and penetration to thickness ratio is 0.2. Neglect friction.

A shear of 20mm (S=20mm) is now provided on the blade. Assuming force vs displacement curve to be trapezoidal, the maximum force (in kN) exerted is

In the deep drawing of cups, blanks show a tendency to wrinkle up around the periphery (flange). The most likely cause and remedy of the phenomenon are, respectively,

The thickness of a metallic sheet is reduced from an initial value of 16 mm to a final value of 10 mm in one single pass rolling with a pair of cylindrical rollers each of diameter of 400 mm. The bite angle in degree will be

Match the correct combination for following metal working processes.

  Processes Associated state of stress
P. Blanking 1. Tension
Q. Stretch Forming 2. Compression
R. Coining 3. Shear
S. Deep Drawing 4. Tension and Compression
    5. Tension and Shear

The force requirement in a blanking operation of low carbon steel sheet is 5.0 kN. The thickness of the sheet is ‘t’ and diameter of the blanked part is ‘d’. For the same work material, if the diameter of the blanked part is increased to 1.5 d and thickness is reduced to 0.4 t, the new blanking force in kN is